System and method for modular construction of a dome structure and assembly components for facilitating same

ABSTRACT

A system and method for creating a dome structure. The method comprises forming a plurality of sections, each section include a top shoulder plate, a bottom shoulder plate, and a plurality of ribs disposed therebetween. The ribs and shoulder plates have an arc-shaped cross-section. The method further includes placing at least two of the sections adjacent to one another to produce a first ring. Respective top shoulder plates, ribs and bottom shoulder plates are secured together. At least two of the sections are placed adjacent to one another to produce a second ring. The second ring is placed on top of the first ring, the second ring having a cross-sectional area smaller than a cross-sectional area of the first ring.

BACKGROUND OF THE INVENTION

The invention relates to a system and method for creating a domestructure and, more particularly, to a system and method enabling asimple, modular manufacture of a dome.

Dome structures, used for centuries by humankind, are noted for theirstrength and stability as a result of double arch configurations thatcarry and resist loading in various directions. Wooden domes are highlyearthquake and hurricane resistant, as dome shapes resist movementdamage better than conventional buildings and wood structures are moreflexible than concrete. Domes also provide unique aesthetics inside andout, rich acoustics inside and considerable design flexibility.

During the past 50 years, dome construction has largely taken the formof monolithic concrete structures or wooden geodesic structures, both ofwhich have inherent drawbacks. A monolithic structure (such as concretedomes) generally needs to be created completely on site. Due to the sizeand weight of such structures, transportation maybe difficult if notimpossible. Moreover, in most cases there is little flexibility indesign that is often limited in its size or configuration and it maytake a long time to actually manufacture the structure. Concrete is notecologically friendly. Geodesic structures produce an appearance that ismulti-faceted that cause potential roof leakage. It is also lessaesthetically pleasing than monolithic structures.

Thus, there is a need in the art for a system and method for producingan aesthetically pleasing dome structure which can be easilymanufactured, is resistant to weather and is environmentally friendly.There is also a need for a system that can be shipped easily todifferent site location and easily and quickly assembled on site toprovide versatile structures that meets the various needs.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide amethod and system that enables construction of dome-shaped structuresrapidly, easily, and inexpensively.

Another object of the invention is realized in a method and system whichinvolves the creation of a dome structure including by forming aplurality of sections, each section including top and bottom platestructures comprising top and bottom plates, two top shoulder plates,two bottom shoulder plates, and a plurality of ribs disposedtherebetween, the ribs and all plates having an arc-shaped,cross-section. The respective top and bottom plates, top shoulderplates, ribs and bottom shoulder plates are secured together and two ofthe sections or more are placed adjacent to one another to produce afirst ring. This is based on the size of sections manufactured. Thesections can be manufactured with any sizes to suit the needs, takinginto consideration the transportation and the site assemblyrequirements. A second ring is formed atop the first ring by placing anumber of sections adjacent to one another to produce the second ringatop the first ring, with the second ring having a cross-sectional areasmaller than the cross-sectional area of the first ring. This could bedifferent for an outward bulging dome shape. The height of rings isvariable, as is the length of the sections.

Preferably, the dome sections are made of wood, although the use ofother materials is feasible. In accordance with various embodiments ofthe invention, there may be seven ribs disposed between the top andbottom shoulder plates. The ribs in the second ring may be placed closerto one another than the ribs in the first ring. In general ribs arespaced at specific distance at the bottom of each section. This isdetermined by the designer. The most common spacing is 16 inches oncenter. The ribs may be spaced closer on the top of each section thanthe bottom. Also, while the rib spacing at the bottom is generally thesame throughout the sections (the entire dome), the spacing at the topof the section gets smaller the higher the location of the section onthe dome. This provides the required dome shape or configuration. Thisis the other way around in case of an outward dome shape or the insideof a donut shaped structure. Strapping and sheeting may be provided tothe exterior of the rings to provide a finished look. Preferably, thestrapping is applied on the exterior in one or several layers and on theinside in one layer. Insulation may be disposed in the interior of therings to obtain a more insulated construction and the sub-components ofthe section may be secured to one another using tongue and groovefastening mechanisms or other mechanical means.

The invention includes the provision of an assembly machine which can beused to produce the individual sections. The assembly machine mayinclude a plurality of adjustable arms that enable the length of theribs (the height of the section) to be accommodated.

Each rib holder is rotatable with respect to a base portion about afirst axis. Each rib holder includes an arm whose angle is adjustablewith respect to a base portion so as to be rotatable about a second axisperpendicular to the first axis. Each rib holder further includesgripping members effective to hold the rib therein, in a manner wherebya plurality of sections of different members of ribs and spacing betweenribs may be produced easily using the assembly machine.

The machine preferably has an odd number of arms, for example, 5, 7, 9,etc., that varies, but typically accommodates seven ribs. Each arm has abase that moves on a specific calculated arc track on the table. This istrue for all arms except the middle one that is fixed in place. The baseof the arms move on these tracks to form an arc that is required inmanufacturing the desired sections. All arms rotate on their basestypically from 0 to 90 degrees around an axis that is perpendicular tothe track that the base moves on. This axis touches an inner lower pointof the section produced, i.e., the arm rotates around the inner point ofthe bottom shoulder plate. On each arm there are two movable angledsockets that are adjustable to provide the height of section (the lengthof the rib). Once the number of the desired section is produced, themachine is readjusted to produce the other sections. Again, this is doneby moving the bases of the arms on the tracks on the table to producethe desired arc, then rotating the arm on the base to the desired angleand adjusting arm to the required length (in general the height of thesections is the same throughout the dome structure so there is no needto readjust). At this point the shoulder plates and the ribs are placedin place and nailed or stapled together.

The assembly machine can be used at a factory site and the individualdome sections shipped to a construction site. Alternatively, theassembly machine can be utilized directly at a construction site.Several assembly machines may be utilized for one or several differentdome constructions, with different machines designed to provide sectionsof different numbers of ribs, for example, a first machine for sevenribs, a second nine and a third for handling eleven ribs, and so on.

The method for creating a dome structure comprises forming a pluralityof sections, each section including top plate structure, a bottom platestructure, and a plurality of ribs disposed therebetween, the ribs andplate structure having an arc-shaped cross-section; securing togetherrespective top plate structures, ribs and bottom plate structures;placing at least two of the sections adjacent to one another to producea first ring; placing at least two of the sections adjacent to oneanother to produce a second ring; and sections of the second ringbecoming located on top of the first ring, the second ring having across-sectional area smaller than a cross-sectional area of the firstring. The second, third, fourth, etc., rings can be optionally fullyassembled rings and then placed atop the previous ring or they can beformed in sections and then placed atop a lower ring or actuallyassembled on top of the lower ring. The entire ring or the entire domecan be produced in one piece.

Other features and advantages of the present invention will becomeapparent from the following description of the invention which refers tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a dome in accordance with an embodimentof the invention.

FIG. 2 is a front view of a section used to produce a dome in accordancewith an embodiment of the invention.

FIG. 3 is a perspective view of a section used to produce a dome inaccordance with an embodiment of the invention.

FIG. 4 is a side cut-away view of a portion of a section used to producea dome in accordance with an embodiment of the invention.

FIG. 5 is a top view of a shoulder plate used to produce a section inaccordance with an embodiment of the invention.

FIG. 6 is a side cut-away view of a first ring implanted into the groundto produce a dome in accordance with an embodiment of the invention.

FIG. 7 is two perspective views of an assembly machine for assembling adome in accordance with an embodiment of the invention.

FIG. 8 is four perspective views of an assembly machine for assembling adome in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, there is shown a dome 50 which may be constructedin accordance with an embodiment of the invention. Dome 50 is comprisedof a plurality of sections 52. Sections 52 are installed in the ground54 and disposed adjacent to one another so as to form a ring 56 having asubstantially circular or elliptical cross-section when viewed fromabove in the direction of arrow 51. Rings 56 having successively smallercross-sections are stacked on one another to form dome 50. Seven rings56 a, 56 b, 56 c, 56 d, 56 e, 56 f, 56 g are shown in the figure. Aspace may be defined by each ring 56 so as to create an opening, such asopening 58. Opening 58 may be used for a window or door or the like.

Referring to FIGS. 2, 3, 4 and 5, there are shown a plurality of viewsof section 52. Each section 52 is comprised of an odd number (5, 7, 9,etc.) of ribs 60. Ribs 60 extend vertically when used in a dome 50 andare comprised of studs—such as 2 inches by 4 inches wood studs. Each rib60 may be, for example, 21 inches by 3 inches by 2 inches. Each section52 may include the same number, for example seven, ribs. The center tocenter distance between ribs 60 at a bottom most ring 56 may be 16inches. This produces smaller distances at the top of the section andthe top distances gets less and less the higher the ring or the sectionis located on the dome even though the spacing of the ribs through outthe entire dome structure at the bottom of the sections or rings may bethe same. This change in width helps form the dome shape. The shoulderplate dimensions may be 2″ to 5″ deep and ⅜″ thick. For example, if thebottom length of a section is 9′ and the top length of this section is8′, another section that is located above this section will have a toplength under 8′ when the bottom length is 9′. And so on. Ribs may changein size, but need not.

An upper shoulder plate 62 and lower shoulder plate 64 are attached toribs 60 at top and bottom portions respectively. As shown most clearlyin FIGS. 3 and 5, shoulder plates 62, 64 have an arc-shapedcross-section when viewed from the top or bottom. As shown most clearlyin FIG. 4, each shoulder plate 62, 64, has a U-shaped cross-section whenviewed from the side. The U-shape defines a groove effective to receivea tongue 66 of a respective rib 60. Clearly other fastening structuresaside from tongue and groove may be used to combine shoulder plates 62,64 with respective ribs 60. The walls of the U-shape may be ⅜″ in widthand made of OSB (oriented strand board) sheets. Each rib 60 alsogenerally has (but need not have) an arc-shape cross section, and thedistal ends of the ribs preferably have angled cuts so that a top-mostpart of a rib is bent more inwardly toward a center of dome 50 than abottom-most portion of the rib. As shown in FIG. 3, at a corner of eachsection 52, a solid blocking stiffener 67 may be used to enhancestructural integrity. Stiffener 67 may be 2¼″×2″×6″.

A plurality of sections are disposed adjacent to one another and ribsfrom adjacent sections are fastened together using, for example, OSBsheathing and fasteners, so as to form ring 56. Referring to FIG. 6,there is shown a side cut-away view of a first ring 56, R1 installedinto the ground 54. As shown, ½″ anchor bolts may be used to anchorbottom shoulder plate 64 of the first section 52 of first ring 56, R1into ground 54. As shown in FIG. 1, a diameter of each ring 56 issmaller than the diameter of a ring vertically beneath it. Rings areconnected to one another through the use of OSB strapping boards andfasteners. Once dome 50 is assembled using sections 52, OSB may beplaced as a shell outside dome 50. Insulation may also be placed insidedome 50 as desired. A mesh or stucco finish or other siding materialsmay be placed outside the sheathing. Inside the dome, stucco or drywallmay be used.

As can be discerned, dome 50 yields a modular construction. Sections 52may be designed and constructed at a first location and shipped to asecond location before being assembled. The assembly is simply performedby laying out a series of sections 52 and fastening them together toform rings.

Referring to FIGS. 7 and 8, there are shown various views of an assemblymachine 80 which may be used to produce a section 52 in accordance withan embodiment of the invention. As shown, assembly machine 80 includes aplurality (e.g., 7) of rib holders 82 so that a distance between ribs ina section may be adjusted. Each rib holder 82 is rotatable with respectto a base portion 84 about a first axis. Each rib holder 82 includes anarm 88 whose angle is adjustable with respect to base portion so as tobe rotatable about a second axis perpendicular to the first axis. Eachrib holder 82 further includes gripping members 86 effective to hold arib 60 therein. In this way, a plurality of sections of differingnumbers of ribs 60 and spacing between ribs 60 may be produced usingassembly machine 80.

A dome construction system in accordance with the invention is unique inthat it yields monolithic dome structures built with conventionalbuilding construction components, in sections that can easily beassembled on site. The unique structure provides a real dome atmosphere,contrary to the many-faceted geodesic dome structures of the prior art.These wooden building systems that take the shape of domes may use smallpieces of waste lumber (e.g., under 14″ long).

These structures have many advantages in addition to their strength andflexibility. They are economical, energy efficient and environmentallysensitive. Each system may be one dome or a number of domes conjoined inany desired fashion, and can be one or multiple story structures. Builtin sections for delivery to construction sites, the system can beapplied to produce domes of any shape and size up to 1,000 feet indiameter and can be used for residential and commercial buildings,industrial and public structures, arenas and stadiums, and emergency andtemporary shelters. For domes greater than 80′ in diameter the system isenhanced by intersecting arches on the inside (similar to the waffleconcrete slab in a way). This is done on site and by using standardlumber.

The dome's light and flexible body makes them virtually earthquake proofand suitable for all regions regardless of snow load, wind andearthquake conditions. Paradoxically, the lighter the building, thebetter the results in earthquake and hurricane tests. A wooden dome inaccordance with the invention is much lighter than concrete domes. Thestructure's life span is expected to be more than twice that ofconventional wood structures, thereby causing less ecological damage asthe environmental impacts of these buildings are spread over a longerperiod.

Construction time is greatly reduced—depending on size, the system takesas little as one to two days to assemble for medium size structures. Inaddition, since job site disturbance is minimal and environmentalimpacts of construction waste disposal are minimized, the system issuitable for environmentally sensitive areas. The domes are avalue-added dream. They can use sawmill trim ends 14 inches long andsmaller, so the construction system is highly ecologically friendly.Waste generated by seven dome buildings equals that of one conventionalbuilding.

The system is energy efficient (providing heating and lighting savingsof 30-50%); flexible (with clear spans and no required interior support,space can be altered easily to accommodate future layout changes); andprovides superior design aesthetics (with open spaces, better aircirculation and improved light distribution). Domes are fine for homesand small buildings. Almost anything can be done architecturally. Shapescould be elliptical, dome shaped or oval, and can even be constructed ontop of rectangular or square foundations. Clear spans are possible tovery large diameters and the structures can have any number of openings.

Although the present invention has been described in relation toparticular embodiments thereof, many other variations and modificationsand other uses will become apparent to those skilled in the art. It ispreferred, therefore, that the present invention be limited not by thespecific disclosure herein, but only by the appended claims.

1. A method for creating a dome structure, the method comprising:forming a plurality of sections, each section including a top platestructure, a bottom plate structure, and a plurality of ribs disposedtherebetween, the ribs and plate structures having arc-shapedcross-sections; placing at least two of the sections adjacent to oneanother to produce a first ring; and placing at least two of thesections adjacent to one another to produce a second ring having across-sectional area smaller than a cross-sectional area of the firstring; and locating the second ring on top of the first ring, and using asufficient number of rings to produce the dome structure.
 2. The methodas recited in claim 1, wherein the top plate structure is constructed soas to include a top plate and at least one top shoulder plate and thebottom plate structure includes a bottom plate and at least one bottomshoulder plate.
 3. The method as recited in claim 2, wherein thesections are made of wood.
 4. The method as recited in claim 2,including assembling seven ribs between the top and bottom shoulderplates.
 5. The method as recited in claim 2, wherein the ribs at the topof the second ring are placed closer to one another than the ribs at thetop of the first ring, while the spacing at the bottom is the same forthe first and second sections.
 6. The method as recited in claim 2,further comprising applying strapping and sheathing to an exterior ofthe rings.
 7. The method as recited in claim 2, further comprisingapplying an insulation to an interior of the rings.
 8. The method asrecited in claim 2, including providing two top shoulder plates and twobottom shoulder plates.
 9. The method as recited in claim 2, includingsecuring the second ring to the first ring.
 10. The method as recited inclaim 2, including providing fewer ribs in the second ring than in thefirst ring.
 11. The method as recited in claim 2, including affixingadjacent sections to one another.
 12. The method of claim 6, includingapplying strapping at the interior of the dome structure.
 13. The methodof claim 1, including physically securing the sections and ringstogether.
 14. A building dome, comprising: a first ring, the first ringincluding at least two sections disposed horizontally adjacent oneanother; a second ring disposed on the first ring, the second ringincluding at least two sections disposed horizontally adjacent to oneanother, the second ring having a cross-sectional area smaller than across-sectional area of the first ring; and each section includes a topplate structure, a bottom plate structure, and a plurality of ribsdisposed therebetween, the ribs and plate structures having anarc-shaped cross-section, wherein respective top plate structures, ribsand bottom plate structures are secured together.
 15. The building domeof claim 14, wherein the top plate structure includes a top plate and atleast one shoulder plate and the bottom plate structure includes abottom plate and at least one shoulder plate.
 16. The building dome ofclaim 15, wherein the plate structures are constructed of a materialselected from the group of materials consisting of: synthetic materials,natural materials, OSB, wood, hemp, metal, sugarcane fiber, and bamboo.17. The building dome of claim 15, wherein the sections are constructedof a material selected from the group of materials consisting of:synthetic materials, natural materials, OSB, wood, hemp, metal,sugarcane fiber, and bamboo.
 18. The building dome of claim 15, whereinthere are seven ribs disposed between the top and bottom shoulderplates.
 19. The building dome of claim 15, wherein top ends of the ribsof the second ring are placed closer to one another than in the firstring, while the rib spacing at the bottom of the first and second ringsis substantially the same.
 20. The building dome of claim 15, furtherincluding strapping and sheathing applied to an exterior of the rings.21. The building dome of claim 15, wherein the second ring is physicallysecured to the first ring, and wherein adjacent sections are physicallyaffixed to one another.